Concrete anchor

ABSTRACT

The invention covers an anchor system for securing an object to a work-piece such as a concrete surface. The system includes an anchor portion with a tubular member extending from an anchor head. The tubular member includes a wall and the wall including a first interior surface. The tubular member also includes a second interior surface having an enlarged diameter with respect to the first interior surface. The system further includes a support portion including a base portion and a shaft portion extending from the base portion. The shaft portion includes a first exterior surface and a second exterior surface of a greater diameter than the first exterior surface and the base portion further includes a central portion. The support portion includes a through passage. A distal end of the shaft portion is received in the interior surface of the wall and a fastener is disposed in the through passage.

CROSS-REFERENCE TO RELATED APPLICATIONS

The following application hereby incorporates by reference and derives priority from U.S. Provisional Application No. 62/114,725, filed on Feb. 11, 2015, now pending.

FIELD OF THE INVENTION

Concrete structures are formed by providing a work-piece or form structure that defines the outer boundaries of the concrete structure to be formed. Concrete is then poured into the form and stays in the form for the prescribed setting period of time. The form can outline a vertical structure such as a wall or a horizontal structure such as a floor or slab. The form is sometimes removed after concrete setting or can be left in the case of structures where it is intended to be a part of the finished structure.

BACKGROUND OF THE INVENTION

It is sometimes desirable after concrete setting and after the form or work-piece is removed to be able to securely connect certain other structures (e.g., a railing, a post, a threaded hanger, etc.) to the concrete structure. One well known method of achieving such a connection is to imbed an anchor having a connector in the concrete before it sets so that after setting the embedded connector can be used for easy secure connection and anchoring.

BRIEF SUMMARY OF THE INVENTION

The anchor system of the present invention provides an innovative solution to the need for making secure connections to poured concrete structures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a first embodiment of an anchor system of the present invention.

FIG. 2 shows an elevation view of the anchor system of FIG. 1.

FIG. 3 shows a cross-sectional view of the anchor system of FIG. 1.

FIG. 4 shows a cross-sectional view of the anchor system of FIG. 1 positioned to be set to a form.

FIG. 5 shows a cross-sectional view of the anchor system of FIG. 1 set in a form.

FIG. 6A shows a cross-section of the anchor portion of the anchor system of FIG. 1 set in concrete and aligned to receive a first diameter male threaded anchor fastener.

FIG. 6B shows a cross-section of the anchor portion of the anchor system of FIG. 1 set in concrete and aligned to receive a second diameter male threaded anchor fastener.

FIG. 7 shows a perspective view of second embodiment of an anchor system of the present invention.

FIG. 8 shows an elevation view of the anchor system of FIG. 7.

FIG. 9 shows a cross-sectional view of the anchor system of FIG. 7.

FIG. 10 shows a cross-sectional view of the anchor system of FIG. 7 positioned to be set to a form.

FIG. 11 shows a cross-sectional view of the anchor system of FIG. 7 set in a form.

FIG. 12A shows a cross-section of the anchor portion of the anchor system of FIG. 7 set in concrete and aligned to receive a first diameter male threaded anchor fastener.

FIG. 12B shows a cross-section of the anchor portion of the anchor system of FIG. 7 set in concrete and aligned to receive a second diameter male threaded anchor fastener.

FIG. 13 shows a top view of the support portion of FIG. 7.

FIG. 14 shows an elevation view of the support portion of FIG. 7.

FIG. 15 shows an elevation view of the support portion of FIG. 7 highlighting certain aspects of the base.

FIG. 16 shows an enlarged view of the highlighted portions of FIG. 15.

FIG. 17 shows an elevation view of an embodiment of the support portion of FIG. 1 including a threaded sealing portion.

FIG. 18 shows a perspective view of the support portion of FIG. 17.

DETAILED DESCRIPTION OF THE INVENTION

The present invention includes an anchor system securable to a work-piece comprising an anchor portion and a support portion. The anchor portion may include a tubular member extending from an anchor head. The tubular member may include a wall and the wall may include a first interior surface. The tubular member may include a second interior surface having an enlarged diameter with respect to the first interior surface.

The support portion may include a base portion and a shaft portion extending from the base portion. The shaft portion may include a first exterior surface and a second exterior surface of a greater diameter than the first exterior surface. The base portion may further include a central portion and the support portion may include a through passage.

A distal end of the shaft portion is received in the interior surface of the wall. Furthermore, a fastener is disposed in the through passage and includes a drive end and a fastening end. The drive end extending from the distal end a predetermined distance. At least a portion of one of the first and second interior surfaces includes threads. In addition, the system includes a first pre-set configuration and a second set configuration and the anchor portion travels telescopically relative to the support potion along a central axis to transition from the first configuration to the second configuration.

A lower portion of the anchor head is able to contact the drive end to drive the fastener during the travel to extend the fastening end into the work-piece. Further, the telescopic travel includes sufficient interaction between the second interior and second exterior surfaces to prevent ingress of concrete to the second interior surface in the set configuration.

The anchor system of the present invention will now be described in detail in conjunction with FIGS. 1-7. FIG. 1 shows a perspective view of an anchor system 10 of the present invention. Anchor System 10 includes an anchor portion 100 and a support portion 200.

Anchor portion 100 includes a head portion 110 and a cylindrical or tubular portion 120 which is elongated and extends from head portion 110. In other words, head portion 110 is connected to an upper portion of tubular portion 120 and can have a flanged arrangement relative to tubular portion 120. In any case, head portion 110 is sized and shaped to receive an impact from a tool such as a hammer and is sized and shaped to transfer load on anchor portion 100 to the concrete. Its flanged arrangement is such that head portion 110 can extend radially past an outermost radial extremity of tubular portion 120. Tubular portion 120 includes a cylindrical or tubular wall 124 having an internal or interior cylindrical surface 128 that defines a generally elongated internal volumetric space.

The cylindrical interior surface 128 can include multiple interior stepped surfaces 130, 132 of different diameter. Therefore, the thickness of cylindrical wall 124 may be reduced as the diameter of the stepped surfaces increases. The stepped surfaces 130, 132 can be directly adjacent one another or non-threaded space may exist between steps. Female threads 134, 136 respectively may be formed on at least a portion of at least one of stepped interior surfaces 130, 132 and may be formed on two or more interior surfaces. The threads may extend up to the entire length of one or all of the stepped surfaces or may extend just a small radial length thereof. The cylindrical surface 130, 132 and threaded portions can increase in diameter the farther away they are from head portion 110 or decrease the closer they are to head portion 110.

Furthermore, the cylindrical stepped interior surfaces 130, 132 include at least an upper reduced diameter surface 130 that is reduced relative to a lower enlarged diameter surface 132.

As mentioned above Anchor system 10 also includes a support portion 200. Support portion 200 includes a shaft portion 240 connected to a base portion 220. Shaft portion 240 extends upward from base portion 220 as shown in FIG. 3 and terminates in a distal end 252. Shaft portion 240 includes a cylindrical or tubular wall 242. Tubular wall 242 includes an exterior surface 243 that can have multiple stepped diameter surfaces in the longitudinal direction. The exterior surface 243 includes at least a lower increased diameter exterior surface portion 248 relative to an upper decreased diameter exterior surface portion 244. Outer surface steps 244, 248 may decrease in diameter longitudinally as shaft portion 240 extends away from base portion 220. Shaft wall 242 also includes an inner wall surface defining a longitudinal through passage 260.

Base portion 220 can include a central portion 256 to which the shaft portion 240 is connected. Central portion 256 also includes a through passage. Through passage 260 extend entirely through a longitudinal centerline of support portion 200. Base portion 220 can be molded to the shaft portion 240 as one continuous piece or can be attached as two pieces.

Central portion 256 includes a lowermost surface 257. A skirt 262 may extend radially outward and downward from central portion 256. Skirt 262 can be made of a flexible material and can extend downward longitudinally past lowermost surface 257. Therefore, when lower surface 257 of base portion 220 is urged into contact with a work-piece 400 such as a wooden form (see FIG. 4), it may first contact skirt 262 which flexibly relaxes and deforms until lowermost surface 257 also contacts work-piece 400. Skirt 262 may therefore be biased against work-piece 400 when both are in contact with work-piece 400 to create an active seal against concrete getting between skirt 262 and work-piece 400. Flexible skirt 262 may also deform to comply with minor inconsistencies in the surface of work-piece 400 to which anchor system 10 is fastened via nail or screw 300. Longitudinal through passage 260 may receive a fastener 300 such as a nail or a screw.

To assemble anchor system 10, distal end 252 is inserted into tubular portion 120 of anchor member 100. First exterior surface 244 of shaft portion 240 is received by first interior surface 130. Furthermore, second exterior surface 248 is received by second interior surface 132 of tubular member 120. Specifically, a diameter of first exterior surface 244 is slightly smaller than the thread tip diameter of first threads 134 of first interior surface 130 of tubular portion 120. In addition, second exterior surface 248 is slightly smaller than the thread tip diameter of second thread 136 of second interior surface 132. Three or more corresponding step portions on tubular portion 120 and correspondingly on shaft portion 240 may also be employed in a similar manner.

Each step 130, 132 of tubular portion 120 of anchor portion 100 therefore slides telescopically in contact with its corresponding stepped shaft portion 244, 248 so that a longitudinal center line of shaft portion 240 is aligned or collinear with a longitudinal centerline of tubular member 120.

The lowermost increased diameter exterior surface 248 of shaft portion 240 contacts a corresponding lowermost interior surface 132 of tubular portion 120 in a sufficiently snug manner to prevent concrete from entering the tubular portion before the concrete sets. Specifically, each different shaft diameter 244, 248 slides telescopically into a corresponding tubular space of tubular member 120.

There are two configurations of anchor system 10. In the first pre-set configuration, (shown in FIG. 3) a fastener 300 (e.g., a nail or screw) is received in the central or through passage 260 of shaft 240. An extension portion of the nail proximate a drive end 310 of fastener 300 extends above a distal end 252 of shaft portion 240. The extension portion is disposed within the tubular space in first interior surface 130 and with the head of fastener 300 in contact with a lower portion 112 of head portion 110.

Also in the first pre-set configuration, as discussed above the first interior surface 130 telescopically receives first exterior surface 244. In addition, second interior surface 132 may also receive a portion of second exterior surface 248 for increased alignment guidance. Furthermore, in a certain configuration just a portion of second exterior portion 248 of shaft portion 240 may be in telescopic contact with second interior surface 132 without initial telescopic contact between First exterior surface 244 and first interior surface 130. In other words in a certain configuration, second interior surface 132 may overlap second exterior surface 248 before distal end 252 enters first interior surface 130.

Anchor system 10 is reconfigurable from the pre-set condition of FIGS. 3 and 4 to the set configuration shown in FIG. 5 by applying an impact force (e.g., by a hammer) to the top of head portion 110 of anchor portion 100. The various interior threaded stepped portions of the anchor portion 130, 132 then telescopically slide longitudinally along the corresponding exterior surfaces of shaft portion 240. Ultimately, distal end 252 of shaft potion 240 containing a drive end 310 of fastener 300 contacts a lower portion of head portion 110. In any case, a sufficient length of second interior surface 132 must have telescopically slid over a sufficient portion of second exterior surface 248 that a seal against ingress of setting concrete is established. In one configuration, during impact relative telescopic movement between anchor portion 100 and support portion 200 stops when lower portion 112 of head portion 110 contacts distal end 252 (possibly via drive end 310). In other configurations, such relative movement may be stopped when stop step 138 of tubular portion 120 engages another stop step 246 of shaft portion 240.

Furthermore, during impact fastener 300 is driven through support portion 200 extending from central portion 256 and into the form or work-piece 400 to set the anchor system 10. Fastener 300 may either be smooth or profiled (e.g., ringed nail). Ring nails provide a strong grip to the work-piece and improves robustness prior to and during concrete placing. The telescopic repositioning during impact is such that second interior surface 132 relates to second exterior surface 248 sufficiently snuggly that concrete material cannot enter between second threads 136 and second exterior surface 248 of tubular portion 120 after concrete pouring and before concrete setting when set concrete surrounds anchor system 10. In other words skirt 262 is capable of absorbing energy due to an inadvertent or accidental blow by a worker while maintaining the intended set configuration of the anchor 10.

After setting, support portion 220 is removed to expose first and second threads 134, 136 on the interior of tubular portion 120 as shown in FIG. 6A and 6B. To do so, an installer may grasp support portion 200 (e.g., by fastener 300), central portion 256, skirt 262, or by any other structure of support portion 200 exposed in the set concrete. FIG. 6 also shows how multiple diameter threaded rods or bolts 600 and 610 may be aligned with first or second threads 134, 136 according to guide lines 602 and 612 respectively to be securely anchored to anchor portion 100. After setting, flexible skirt 262 has at least one additional benefit. In the case where an anchor is hit from the side after installation, support member 200 via flexible skirt 262 is able to urge anchor member 100 back to an originally intended orthogonal, angled or otherwise aligned configuration with respect work-piece 400.

FIGS. 7-16 show another embodiment of the anchor system of the present invention. Corresponding reference numbers from the embodiment of FIGS. 1-6 apply to the embodiment of FIGS. 7-16. In addition, base portion 220 includes a rim or ridge 259 thereon which defines a seat 258 into which a distal end 122 of tubular portion 120 rests and engages in the set configuration shown in FIG. 11. Ridge 259 projects upward from base portion 220 to engage an outer surface of tubular portion 120. As with the embodiment of FIGS. 1-6, the engagement between distal end 122 and seat 258 functions to prevent ingress of concrete to interior surface 128. In addition, various materials (e.g., rubber or foam) may be provided at second threads 136, at, inside, or within a lower end of tubular portion 120 and for interaction with second exterior surface 248 in order to prevent concrete from entering second thread 136. The material can be in the form of a ring. Alternatively, a ring or threads of such material can be placed on second exterior surface 248 for frictional interaction with threads 136. FIGS. 17 and 18 show such a ring structure in a threaded form around an exterior surface 248 for frictional interaction with a female structure supported from a distal end of tubular portion 120. Frictional interaction with the threaded and female portions deter ingress of concrete as discussed above.

The present system discusses a two step threaded member. However, three or more steps may be utilized. The disclosure above also applies to three or more steps where the upper and lower steps are described as above, but one or more steps are added between the above described upper and lower steps. Furthermore, for each threaded step there is a corresponding shaft step that is telescopically received in each threaded step. Moreover, horizontal cross sections of the present invention as shown are generally circular, but may be polygonal or of another shape. 

1. An anchor system securable to a work-piece comprising: An anchor portion including a tubular member extending from an anchor head, the tubular member including a wall and the wall including a first interior surface, the tubular member including a second interior surface having an enlarged diameter with respect to the first interior surface; A support portion including a base portion and a shaft portion extending from the base portion, the shaft portion including a first exterior surface and a second exterior surface of a greater diameter than the first exterior surface, the base portion further including a central portion and the support portion including a through passage; a distal end of the shaft portion received in the interior surface of the wall, a fastener disposed in the through passage and including a drive end and a fastening end, the drive end extending from the distal end a predetermined distance, wherein at least a portion of one of the first and the second interior surfaces including threads, and wherein the system includes a first pre-set configuration and a second set configuration and the anchor portion travels telescopically relative to the support potion to transition from the first configuration to the second configuration, and a lower portion of the anchor head able to contact the drive end to drive the fastener during the travel to extend the fastening end into the work-piece, and wherein the telescopic travel includes sufficient interaction between the second interior and second exterior surfaces to prevent passage of concrete to the second interior surface in the set configuration.
 2. The Anchor system of claim 1, wherein the first interior surface is closer to the head portion than the second interior surface.
 3. The anchor system of claim 1, wherein the one of the first and the second interior surfaces is the first interior surface.
 4. The anchor system of claim 1, wherein the central portion includes a skirt extending therefrom.
 5. The anchor system of claim 3, wherein the first exterior surface contacts the threads to guide the telescopic travel.
 6. The anchor system of claim 1, wherein the one of the first and the second interior surfaces is the second interior surface.
 7. The anchor system of claim 6, wherein the second exterior surface contacts the threads to guide the telescopic travel.
 8. The anchor system of claim 1, wherein the one of the first and second interior surfaces is at least a portion of the first and a portion of the second.
 9. The anchor system of claim 8, wherein the first and second exterior surfaces contact respective threads to guide the telescopic travel.
 10. The anchor system of claim 1, wherein the base portion further includes an upwardly extending ridge and wherein the ridge contacts an outer surface of the tubular member when the anchor system is in the set configuration.
 11. The anchor system of claim 10, wherein the ridge is an arcuate ridge.
 12. The anchor system of claim 1, wherein a distal end of tubular portion 120 is received in seat.
 13. The anchor system of claim 12, wherein the seat has a u-shaped cross section.
 14. The anchor system of claim 1, wherein the anchor portion is made of a metal material.
 15. The anchor system of claim 1, wherein the support portion is made of a flexible material.
 16. The anchor system of claim 1, wherein the support portion includes a skirt.
 17. The anchor system of claim 16, wherein the skirt extends radially outward and downward from the central portion.
 18. The anchor system of claim 16, wherein the central portion and the skirt contact the work-piece in the set configuration. 